Metallisation: Reliable Thermal Spray Systems for Industrial Protection & Performance
Table of Contents
- Metallisation: A Foundation for Industrial Performance and Asset Protection
- How Metallisation Technology Works
- Core Thermal Spray Systems and Consumables
- Industrial Applications of Metallisation
- Infrastructure & Energy
- Extreme Environments
- Manufacturing, Marine & Reclamation
- Automotive & Industrial Components
- Specialised Applications
- Partnering with Minex for Metallisation Solutions
Metallisation: A Foundation for Industrial Performance and Asset Protection
Metallisation is a cornerstone of modern industry, providing protective layers that shield steel and other metals against corrosion, wear, and harsh environmental conditions. By applying metallic or ceramic coatings, thermal spray processes extend the lifespan of assets, improve efficiency, and ensure compliance with demanding operational standards.
For engineers, operations managers, and procurement specialists, choosing the right system—whether electric arc metallisation or flame metallisation—directly affects reliability, lifecycle costs, and production safety. Coatings based on zinc, aluminium, and specialised alloys are widely used for their proven anti corrosion protection, while ceramic applications deliver resilience under extreme temperature and pressure.
How Metallisation Technology Works
At the heart of thermal spray equipment lies a simple principle: a feedstock material, in wire or powder form, is melted and sprayed onto a treated substrate. This molten metal or molten material is propelled by compressed air, creating a dense, durable coating that bonds securely with the base surface.
Different application methods are selected depending on the project type and required properties:
- Electric Arc Metallisation (including twin wire arc spray): Two electrically charged wires form an arc. The resulting molten metal is atomised by compressed air and evenly sprayed onto the prepared surface. This method is fast, cost-effective, and ideal for applying zinc coatings or aluminium alloys as anti corrosion coatings.
- Flame Metallisation: A combustion flame melts the wire or powder feedstock, producing versatile coatings for protective or decorative purposes.
- Thermal Metallisation for Ceramic Materials: Applied in extreme environments, this method creates high-performance coatings for aerospace, chemical, and nuclear industries.
The process always begins with surface preparation—typically blasting—to ensure strong contact and bonding between the coating and substrate. Once applied, additional paint or powder layers can further enhance protection and aesthetics, creating multi-layered solutions tailored to industrial needs.
Core Thermal Spray Systems and Consumables
Electric Arc & Flame Metallisation Systems
High-speed systems that apply zinc, aluminium, or alloy coatings to protect large structures or reclaim worn parts. Unlike hot-dip galvanisation, the substrate remains cool, eliminating risk of distortion. Additional paint layers can be added to extend durability.
Explore High-Speed Protection: Electric Arc Metallisation Systems and Flame Metallisation Systems
Thermal Metallisation Systems for Ceramic Materials
Designed for components facing severe thermal and mechanical stress. Ideal for chrome replacement, aerospace turbines, and nuclear applications, these systems deliver effective, long-lasting performance.
Explore Extreme Condition Solutions: Thermal Metallisation Systems for Ceramic Materials
Thermal Spray Wires and Powders
Zinc, aluminium, alloys, and pure metals form the backbone of the metallisation process. Their quality directly defines the coating’s performance, making them indispensable for electronics, automotive, and manufacturing applications.
Explore Consumables: Metallisation Wires and Powders
Metallisation Halls and Cabins
Turnkey infrastructure for large-scale or high-throughput projects. From shipyards to offshore wind, these facilities integrate equipment, ventilation, and accessories for safe, efficient operations.
Explore Infrastructure: Metallisation Halls and Cabins
Industrial Applications of Metallisation
Infrastructure & Energy
Exposed steel bridges, balconies, and reinforced concrete face continuous corrosion risks. Electric arc metallisation with zinc coating is the industry standard for these applications, offering reliable long-term anti corrosion protection. In oil & gas, thermal spray aluminium ensures pipelines, tanks, and offshore assets resist both wear and corrosive attack. Wind power, particularly offshore, depends on zinc sprayed coatings in metallisation halls or cabins to guarantee turbine longevity and efficiency.
Explore Electric Arc Metallisation Systems and Metallisation Wires & Powders for infrastructure & energy solutions.
Extreme Environments
In aerospace, chemical processing, and nuclear power, components are exposed to extreme heat, cavitation, and chemical erosion. Conventional coatings cannot withstand these conditions. Thermal metallisation systems for ceramic materials are specifically engineered to provide stability and protection under the harshest operating parameters. They also offer sustainable chrome replacement options, balancing environmental compliance with technical performance.
Discover Thermal Metallisation Systems for Ceramic Materials and Metallisation Wires & Powders for extreme environments.
Manufacturing, Marine & Reclamation
Marine vessels, ship propellers, and offshore structures require robust anti corrosion coatings. Electric arc and flame metallisation provide the necessary durability for these harsh conditions. In manufacturing, metallisation restores critical parts such as moulds, fasteners, cookware, and mill rolls, extending their service life. In steel production, flame and arc spraying maintain rolls and pipes. The electronics sector benefits from pure metallic thermal spray wires without binders, producing precise coatings for sensitive applications.
View our Flame Metallisation Systems, Electric Arc Metallisation Systems, and Metallisation Halls & Cabins for manufacturing and marine projects.
Automotive & Industrial Components
Metallisation enhances the performance and durability of automotive parts, including exhaust systems, seat frames, and fasteners. In tube and pipe manufacturing, coatings protect components such as balustrades and children’s play area equipment, extending their safe service life.
Explore Electric Arc Metallisation Systems and Metallisation Wires & Powders for automotive and industrial applications.
Specialised Applications
Beyond heavy industry, metallisation proves its versatility across a wide range of uses. Paper and print sectors use metallisation for reclaiming ball bearing seats and corroded cylinders. Film and decorative industries apply metallised coatings for both protection and visual effect. LPG cylinders and gas bottles gain long-term corrosion solutions from flame and arc metallisation.
Check Flame Metallisation Systems and Metallisation Wires & Powders for specialised applications.
Partnering with Minex for Metallisation Solutions
Every industry faces distinct challenges. At Minex, we combine consulting expertise with a complete technology portfolio—electric arc, flame, and ceramic metallisation systems, supported by high-quality wires, powders, halls, and cabins. Our solutions are engineered to meet the most demanding requirements, ensuring durable coatings that reduce risk, extend asset life, and deliver measurable ROI.
→ Talk to our experts today to identify the most effective metallisation solution for your operations.
Frequently Asked Questions on Industrial Metallisation
How does metallisation differ from hot-dip galvanisation?
Unlike hot-dip galvanisation, electric arc metallisation sprays molten wire or powder onto the substrate without heating the base metal to extreme temperatures. This process prevents distortion of large steel structures and allows coatings to be applied on-site, even after fabrication or repair, providing greater flexibility and time efficiency.
When should I choose electric arc metallisation over flame metallisation?
- Electric arc metallisation (also commonly referred to as twin wire arc spray) is faster, more cost-effective, and ideal for applying zinc coatings or aluminium alloys for anti corrosion protection on large steel structures such as bridges, pipelines, and offshore platforms.
- Flame metallisation offers greater versatility and is often preferred for smaller-scale, decorative, or repair applications. It is widely used in workshops or mobile operations due to its adaptability to different project sizes and types.
What role do metallisation wires and powders play in coating performance?
The quality and composition of thermal spray wires and powders directly impact corrosion protection, bond strength, and coating durability. Zinc and aluminium wires supply proven anti corrosion coatings, while specialised ceramic powders provide resistance in extreme environments. Choosing the right product is essential to achieving long-lasting, effective protection.
What are metallisation halls and cabins, and why are they important?
Metallisation halls and cabins are dedicated facilities designed for large-scale or continuous metallisation projects. They combine electric arc and flame spray systems with ventilation, dust extraction, and safety accessories to ensure consistent coating quality, operator protection, and environmental compliance. These controlled environments enable efficient production of durable coatings on large steel parts and structures.
Which industries benefit most from thermal metallisation with ceramic materials?
Thermal metallisation systems for ceramic materials are commonly used in aerospace, chemical processing, and nuclear industries. These sectors require coatings that withstand extreme heat, cavitation, and chemical attack. Ceramic coatings also provide a sustainable alternative to chrome plating, supporting environmental regulations while delivering durable corrosion protection.
How does surface preparation affect metallisation quality?
Proper surface preparation, typically by abrasive blasting, is crucial for metallisation success. It removes rust, oils, and contaminants, creating an ideal surface profile that enhances coating adhesion. Well-prepared substrates ensure the sprayed metal bonds effectively, providing long-lasting corrosion protection and reducing the risk of coating failure.
What maintenance is required for metallisation equipment?
Regular maintenance of thermal spray equipment—including spray guns, wire feed units, and compressed air systems—is essential for consistent coating application. Cleaning dust extraction filters and storing consumables properly to prevent oxidation and contamination also prolong equipment life and maintain product quality.